Real-time interactive modeling and simulation process for factory layout

Abstract

Method, system, and computer program product for simulating the layout and flow of a manufacturing facility. An initial facility layout concept and a baseline input data set are received which define placement and movement of virtual objects within a virtual facility model. At least one of several analyses is performed based on the initial facility layout concept and the baseline input data set. An event flow analysis that outputs timing for movement of the objects from the initial positions may be performed. A geometric flow analysis that outputs interactions between the objects resulting from the movements from the initial positions may be performed. An ergonomic analysis that outputs human postures and motions resulting from interactions with objects may be performed. A simulated flow model for the manufacturing facility is generated. A three-dimensional virtual environment of the simulated flow model is generated and output for display.

What is claimed is: 
     
       1. A method for simulating a layout and flow of a manufacturing facility, comprising:
 receiving an initial facility layout concept, wherein the initial facility layout concept includes three-dimensional models of a plurality of objects in a virtual facility model and initial positions of the plurality of objects in the virtual facility model; 
 receiving a baseline input data set for the plurality of objects in the manufacturing facility; 
 based on the initial facility layout concept and the baseline input data set, performing, using one or more computer processors,
 an ergonomic analysis that outputs human postures and motions resulting from interactions of human objects with other objects from among the plurality of objects according to an ergonomic analysis application; 
 
 generating, using the one or more computer processors, a first simulated flow model for the manufacturing facility based on the initial facility layout concept and the ergonomic analysis; 
 generating, using the one or more computer processors, a first three-dimensional virtual environment of the first simulated flow model; 
 generating a plurality of views of the first three-dimensional virtual environment for simultaneous display on a plurality of display screens, each view of the plurality of views representing a different viewing perspective of the first three-dimensional virtual environment; 
 and 
 determining, using the one or more computer processors, that the first simulated flow model for the manufacturing facility is not satisfactory based on determining that a result of the first simulated flow model relating to the manufacturing facility exceeds a threshold value relating to a posture of a human object in the first simulated flow model, and in response:
 automatically, using the one or more computer processors, modifying a height of an object in the baseline input data set, related to the posture of the human object, to generate a modified input data set; 
 generating, using the one or more computer processors, a second simulated flow model for the manufacturing facility based, at least in part, on the modified input data set, wherein the posture of the human object changes for the second simulated flow model relative to the first simulated flow model; 
 generating, using the one or more computer processors, a second three-dimensional virtual environment of the second simulated flow model; and 
 altering at least one of a physical layout and flow of the manufacturing facility based on the second simulated flow model. 
 
 
     
     
       2. The method of  claim 1 , further comprising:
 receiving a point of view input from an input device indicating a location and direction of view, wherein generating the plurality of views of the first three-dimensional virtual environment comprises generating a first view representing a perspective at the indicated location and direction of view; and 
 receiving a second point of view input from an input device indicating a second location and a second direction of view, wherein generating the plurality of views of the first three-dimensional virtual environment further comprises generating a second view representing a second perspective at the indicated second location and second direction of view on a second display screen, wherein the first view and the second view are suitable for simultaneous display on a first display screen and a second display screen. 
 
     
     
       3. The method of  claim 1 , further comprising: based on the modified input data set, performing
 a modified ergonomic analysis that outputs human postures and motions resulting from interactions of the human objects with the other objects from among the plurality of objects according to the ergonomic analysis application,
 wherein the second simulated flow model for the manufacturing facility is based on the initial facility layout concept and the modified ergonomic analysis; and 
 
 displaying the second three-dimensional virtual environment on a computer display screen. 
 
     
     
       4. The method of  claim 3 , wherein the modified input data set is further based on a received user selection. 
     
     
       5. The method of  claim 1 , further comprising:
 performing, based on the initial facility layout concept and the baseline input data set and using the one or more computer processors:
 an event flow analysis that outputs timing for movement of the plurality of objects from the initial positions according to an event flow analysis application, wherein the event flow analysis generates timing for movement of the plurality of objects based on times for movement and speeds for movement from the baseline input data set. 
 
 
     
     
       6. The method of  claim 1 , further comprising:
 performing, based on the initial facility layout concept and the baseline input data set and using the one or more computer processors:
 a geometric flow analysis that outputs interactions between the plurality of objects resulting from the movements from the initial positions according to a geometric flow analysis application, wherein the geometric flow analysis generates interactions between the plurality of objects based on three-dimensional boundaries of the plurality of objects. 
 
 
     
     
       7. The method of  claim 1 , further comprising:
 performing, based on the initial facility layout concept and the baseline input data set and using the one or more computer processors:
 a geometric flow analysis that outputs interactions between the plurality of objects resulting from the movements from the initial positions according to a geometric flow analysis application, wherein the geometric flow analysis generates interactions between the plurality of objects based on articulation models of the plurality of objects. 
 
 
     
     
       8. The method of  claim 1 , wherein the ergonomic analysis generates human postures and motions based on positions of human objects among the plurality of objects and locations of work pieces. 
     
     
       9. The method of  claim 1 , further comprising:
 determining, automatically using the one or more computer processors, an ergonomic score related to human postures and motions in the first simulated flow model,
 wherein the result that exceeds the threshold value is the ergonomic score, and 
 wherein automatically modifying the baseline input data set to generate a modified input data set comprises modifying the baseline input data set to improve the result that exceeds the threshold value. 
 
 
     
     
       10. The method of  claim 1 , further comprising:
 generating an interactive user interface for overlay over a first view of the plurality of views; 
 modifying the first view to display the interactive user interface; 
 receiving user input through the interactive user interface; and 
 modifying at least one of the initial facility layout concept or the baseline input data set based on the received user input. 
 
     
     
       11. The method of  claim 10 , wherein generating the interactive user interface for overlay over the first view of the plurality of views further comprises:
 identifying a parameter relating to at least one of the initial facility layout concept or the baseline input data set; and 
 determining a value for the parameter and automatically populating the interactive user interface with the determined value for the parameter, wherein the received user input relates to the parameter. 
 
     
     
       12. The method of  claim 5 , wherein the event flow analysis is performed using the one or more computer processors, and wherein performing the event flow analysis comprises:
 determining an estimated length of time for an event flow, and determining a confidence interval for the estimated length of time. 
 
     
     
       13. A computer program product for simulating a layout and flow of a manufacturing facility, the computer program product comprising:
 a computer-readable storage medium having computer-readable program code embodied therewith, the computer-readable program code executable by one or more computer processors to:
 receive an initial facility layout concept, wherein the initial facility layout concept includes three-dimensional models of a plurality of objects in a virtual facility model and initial positions of the plurality of objects in the virtual facility model; 
 receive a baseline input data set for the plurality of objects in the virtual facility model; 
 based on at least one of the initial facility layout concept and the baseline input data set, perform
 an ergonomic analysis that outputs human postures and motions resulting from interactions of human objects with other objects from among the plurality of objects according to an ergonomic analysis application; 
 
 generate a first simulated flow model for the manufacturing facility based on the initial facility layout concept and the ergonomic analysis; 
 generate a first three-dimensional virtual environment of the first simulated flow model; 
 generate a plurality of views of the first three-dimensional virtual environment for simultaneous display on a plurality of display screens, each view of the plurality of views representing a different viewing perspective of the first three-dimensional virtual environment; 
 and 
 determine that the first simulated flow model for the manufacturing facility is not satisfactory based on determining that a result of the first simulated flow model relating to the manufacturing facility exceeds a threshold value relating to a posture of a human object in the first simulated flow model, and in response:
 automatically modify a height of an object in the baseline input data set, related to the posture of the human object, to generate a modified input data set; 
 generate a second simulated flow model for the manufacturing facility based, at least in part, on the modified input data set, wherein the posture of the human object changes for the second simulated flow model relative to the first simulated flow model; and 
 generate a second three-dimensional virtual environment of the second simulated flow model, wherein at least one of the layout and flow of the manufacturing facility is altered based on the second simulated flow model. 
 
 
 
     
     
       14. The computer program product of  claim 13 , wherein the computer-readable program code is further executable to:
 receive a point of view input from an input device indicating a location and direction of view, wherein generating the plurality of views of the first three-dimensional virtual environment comprises generating a first view representing a perspective at the indicated location and direction of view; and 
 receive a second point of view input from an input device indicating a second location and a second direction of view, wherein generating the plurality of views of the first three-dimensional virtual environment further comprises generating a second view representing a second perspective at the indicated second location and second direction of view on a second display screen, wherein the first view and the second view are suitable for simultaneous display on a first display screen and a second display screen. 
 
     
     
       15. The computer program product of  claim 13 , wherein the computer-readable program code is further executable to:
 based on the modified input data set, perform
 a modified ergonomic analysis that outputs human postures and motions resulting from interactions of the human objects with the other objects from among the plurality of objects according to the ergonomic analysis application, 
 wherein the second simulated flow model for the manufacturing facility is based on the initial facility layout concept and the modified ergonomic analysis; and 
 display the second three-dimensional virtual environment on a computer display screen. 
 
 
     
     
       16. The computer program product of  claim 15 , wherein the modified input data set is further based on a received user selection. 
     
     
       17. A system, comprising:
 a computer processor; 
 a display screen; and 
 a computer memory, storing:
 an initial facility layout concept relating to a layout and flow of a manufacturing facility, wherein the initial facility layout concept includes three-dimensional models of a plurality of objects in a virtual facility model and initial positions of the plurality of objects in the virtual facility model; 
 a baseline input data set for the plurality of objects in the virtual facility model; 
 an ergonomic analysis application that, when executed by the computer processor, outputs an ergonomic analysis that includes human postures and motions resulting from interactions of human objects with other objects from among the plurality of objects; and 
 a three-dimensional visual application that, when executed by the computer processor:
 generates a first simulated flow model for a manufacturing facility based on the initial facility layout concept and an ergonomic analysis; 
 generates a plurality of views of a first three-dimensional virtual environment of the first simulated flow model for simultaneous display on a plurality of display screens, each view of the plurality of views representing a different viewing perspective of the first three-dimensional virtual environment; and 
 determines that the first simulated flow model for the manufacturing facility is not satisfactory based on determining that a result of the first simulated flow model relating to the manufacturing facility exceeds a threshold value relating to a posture of a human object in the first simulated flow model, and in response:
 automatically modifies a height of an object in the baseline input data set, related to the posture of the human object, to generate a modified input data set; 
 generates a second simulated flow model for the manufacturing facility based, at least in part, on the modified input data set, wherein the posture of the human object changes for the second simulated flow model relative to the first simulated flow model; and 
 generates a second three-dimensional virtual environment of the second simulated flow model, wherein at least one of the layout and flow of the manufacturing facility is altered based on the second simulated flow model. 
 
 
 
 
     
     
       18. The system of  claim 17 ,
 wherein the ergonomic analysis application is further executable to output a modified ergonomic analysis that outputs human postures and motions resulting from interactions of the human objects with the other objects from among the plurality of objects based on the modified input data set; 
 wherein the second simulated flow model for the manufacturing facility is based on the initial facility layout concept and the modified ergonomic analysis; and 
 wherein the three-dimensional visual application is further executable to output for display the second three-dimensional virtual environment of the second simulated flow model. 
 
     
     
       19. The system of  claim 17 ,
 further comprising a network adapter operable to communicate with a first remote computer and a second remote computer, 
 wherein the first remote computer includes a display screen and an input device operable to receive a first selection of a location and direction of view within the first three-dimensional virtual environment, 
 wherein the second remote computer includes a second display screen and a second input device operable to receive a second selection of a second location and direction of view within the first three-dimensional virtual environment 
 wherein generating the plurality of views of the first three-dimensional virtual environment comprises:
 generating a first view representing a perspective at the first selected location and direction of view; and 
 generating a second view representing a second perspective at the second selected location and direction of view, and 
 wherein the computer processor is configured to transmit the first view to the first remote computer and the second view to the second computer using the network adapter. 
 
 
     
     
       20. The system of  claim 19 , wherein the input device is further operable to receive a user input for the modified input data set;
 wherein the ergonomic analysis application is further executable to output a modified ergonomic analysis that outputs human postures and motions resulting from interactions of the human objects with the other objects from among the plurality of objects based on the modified input data set; and 
 wherein the second simulated flow model for the manufacturing facility is based on the initial facility layout concept and the modified ergonomic analysis; and 
 wherein the three-dimensional visual application is further executable to output for display the second three-dimensional virtual environment of the second simulated flow model.